IS 13204 : 1991

Indian Standard RIGID PHENOLIC FOAM FOR THERMAL INSULATION -- SPECIFICATION

UDC 662.998-036.32-405.8.077

© BIS 1991

BUREAU
MANAK

OF INDIAN

STANDARDS

BHAVAN,

9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002

October 1991

Price Group 2

Thermal Insulation Materials Sectional Committee, CHD 27

FOREWORD This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Thermal Insulation Materials Sectional Committee had been approved by the Chemical Division Council. This standard covers preformed rigid phenolic foam in the form of boards, sheets and blocks intended for thermal insulation within operating temperature range of ­ 180°C to + 130°C. Notes for guidance of users/designers have also been prescribed in Annex A covering aspects such as density, thermal conductivity, protection against moisture and fire, and use at lower temperature. In the preparation of this standard, considerable assistance has been derived from BS 3927 : 1986 'Specification for rigid phenolic foam ( PF )' for thermal insulation in the form of slabs and profiled sections, issued by the British Standards Institution ( BSI ), UK. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960 'Rules for rounding off numerical values (revised)9. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

AMENDMENT NO. 1 MARCH 1999 TO IS 13204:1991 RIGID PHENOLIC FOAM FOR THERMAL INSULATION -- SPECIFICATION
[ Page 2, Table 1, Sl No. (iv), col 2 ] -- Substitute 'permeability' for
'transmission' and 'ng/Pa.s.m' for 'g/Pa.s.m'

( CHD 27 )

Reprography Unit, BIS, New Delhi, India

AMENDMENT NO. 2 DECEMBER 2011 TO IS 13204 : 1995 RIGID PHENOLIC FOAM FOR THERMAL INSULATION -- SPECIFICATION
(Page 3, Annex A, clause A.1.1.5, line 1) -- Substitute `Phenolic' for `polyurethane'.

(CHD 27)

Reprography Unit, BIS, New Delhi, India

IS 13204 : 1991

Indian Standard RIGID PHENOLIC FOAM FOR THERMAL INSULATION -- SPECIFICATION
1 SCOPE 1.1 This standard specifies the requirements and methods of sampling and test for rigid phenolic foam for thermal insulation purposes. It applies to slab ( blocks, boards and profiled sheets ) and profiled sections ( pipe sections and radiused or bevelled lags ) cut from pipes. The nominal temperature range for which the insulation material is suitable is --180 to +130°C without any facing. The material is normally supplied with craft paper facing on both sides. 1.2 This standard is not applicable to continuously extended phenolic foam pipe insulating sections. 2 REFERENCES The following Indian Standards are the necessary adjuncts to this standard: IS No. 3069 : 1965 Title Glossary of terms, symbols and units relating to thermal insulation materials Methods of test for mineral wool thermal insulation materials ( second revision ) Methods for the determination of thermal conductivity of thermal insulation materials ( two slab, guarded hot-plate method ) ( first revision ) 11239 Methods of test for rigid cellular ( Part 5 ) : 1985 thermal insulation materials: Part 5 Volume percent of open and closed cells 11239 Methods of test for rigid cellular ( Part 9 ) : 1985 thermal insulation materials: Part 9 Water absorption 11239 Methods of test for rigid cellular ( Part 11 ) : 1985 thermal insulation materials: Part 11 Compressive strength 11239 Methods of test for rigid cellular ( Part 12 ) : 1985 thermal insulation materials: Part 12 Horizontal burning characteristics 3 TERMINOLOGY For the purpose of this standard, the definitions of the terms, symbols and units given in IS 3069 : 1965 shall apply. 4 REQUIREMENTS 4.1 Composition The material shall consist of phenolic foam of uniform cellular structure. Phenolic foam is a rigid phenol formaldehyde cellular material reduced from the condensation products of phenols and formaldehyde, such as, resoles and novolacs, together with hardeners and other additives, for example, surfactants, blowing agents, fillers, etc.

3144 : 1991 3346 : 1980

Code of practice for industrial 4.2 The rigid phenolic foam faced or unfaced shall application and finishing of ther- conform to the requirements given in Table 1 when mal insulating materials at tempe- tested in accordance with the methods prescribed rature from --80°C to 40°C ( first in col 4 of the Table 1. revision ) 4.3 Standard Sizes and Dimensions 7413 : 1981 Code of practice for industrial In the case of finished boards of all the three types, application and finishing of ther- the sizes shall be either 1.0 m × 0.5 m or 1.22 m × mal insulating materials at tempe- 0.61 m or as agreed to between the purchaser and rature above 40°C and up to the supplier. The size for pipe-section and lags 700°C ( first revision ) shall be 1.0 m or 0.5 m length unless otherwise 11239 Methods of test for rigid cellular agreed to between the purchaser and the supplier ( Part 2 ) : 1985 thermal insulation materials: and the bore shall be the specified outside diameter of the pipe to be lagged. Part 2 Apparent density 11239 Methods of test for rigid cellular 4.4 Thickness ( Part 4 ) : 1985 thermal insulation materials: The material shall normally be supplied in thickPart 4 Water vapour transmission ness of 20, 25, 30, 40, 50, 60, 75, 90 and 100 mm. rate 7240 : 1981 1

IS 13204 : 1991 Table 1 Requirement of Rigid Phenolic Foam ( Clause 4.2 ) Sl No. (1) i) ii) iii) iv) v) vi) vii) viii)
3

Characteristic (2) Density, kg/m Compressive strength at 10 percent deformation, Min, kPa Dimensional stability; percent linear change after 7 days at 70±2°C and 95±5 percent RH, Max Water vapour transmission rate at 38°C and 88 percent RH, g/Pa.s.m, Max Apparent water absorption percent by volume, Max Horizontal burning, mm, Max Closed cell content, percent, Min Thermal conductivity at 53°C after 30 days of manufacture, W/m, °K, Max

Requirement (3) 32-60 100 1.5 5.5 7.5 25 60 0.034

Method of Test, Rcf to (4) IS 3144 : 1991 IS 11239 ( P a r t 11) : 1985 IS 11239 ( Part 2 ) : 1985 IS 11239 ( Part 4 ) : 1985 IS 11239 ( Part 9 ) : 1985 IS 11239 ( Part 12 ) : 1989 IS 11239 ( Part 5 ) : 1985 IS 3346 : 1966

NOTE -- For rigid phenolic foams, the variation from the manufacturer's declared value for density shall not exceed ± 15 percent when tested in accordance with the method prescribed in IS 3144 : 1991 except that nominal thickness shall be used for calculating the density. 4.5 Tolerance The dimensions of the product supplied shall not deviate from those specified by more than the appropriate tolerances given in Tables 2 and 3. For slabs, the permissible thickness deviations shall be ±2 mm. Table 2 Dimensional Tolerances for Pipe Sections and Lags ( Clause 4.5 )
Sl No. Dimensions Permissible Deviations Moulded Cut Pipe Section and Lags mm mm (4) (3) ±3 +2 --0 +3 --0 +2 --0 +3 --0 ±3 +2 --0 +3 --0 +2 --0 +3 --0

5 WORKMANSHIP AND FINISH 5.1 General The insulation shall not have visible defects that would adversely affect its service qualities. 5.2 Profiled Sections 5.2.1 Pipe Sections Pipe sections shall be in two semicircular pieces with the longitudinally mating surfaces flat and in the same plane, so that when the two pieces are put together no gaps exists between the mating surfaces. NOTE -- It is common practice for the mating faces whilst still being flat in the lengthwise direction to have a variable profile in the radial direction. This is acceptable provided that the mating surfaces so created still fit snugly together. In many cases this practice enhances the snugness of the fit. Table 3 Dimensional Tolerances for Slabs ( Clause 4.5 )
Sl No. Lengths or Widths Permissible Deviations < of Lengths or Widths Maximum Difference in the Lengths of the Diagonals of Rectangular, Slabs mm (4) 5 7 Thickness Tolerance

(1)

(2)

i) Lengths ii) Bores less than 150 mm iii) Bores 150 mm and above iv) Outside diameters less than 150 mm v) Outside diameters 150 mm and above

NOTE -- For single-layer components or the first layer of a multi-layer component, the tolerance on the bore is given on the quoted pipe outside diameter. For the second or subsequent layers of multilayer components, it is given on the outside diameter of the mating inner layer.

mm mm (2) (1) (3) ±2 i) Up to and including 1 000 ii) Over 1 000 up to and ±3 including 2 000

mm (5) ±2 ±2

2

IS 13204 : 1991 5.2.1.1 The ends shall be flat and normal to the longitudinal axis of the pipe section. For a single layer pipe insulation system or the first layer of a multi-layer system the permissible deviation on the bore shall be given on the quoted pipe outside diameter. For the second or subsequent layer(s) of multi-layer systems it shall be given on the outside diameter of the mating inner layer. 5.2.2 Radiused and Bevelled Lags The mating bevelled edges shall be flat, so that when they are put together to form a cylinder no gaps exist between abutting lags. The ends shall be flat and normal to the longitudinal axis of the lag. 6 PACKING AND MARKING 6.1 Packing The material shall be packed as agreed to between the purchaser and the supplier. 6.2 Marking The packages shall be legibly and indelibly marked with the following information: a) Indication of the source of manufacture; b) Density of the material; c) Length, thickness and width/nominal bore of the material; and d) Batch or lot number. 7 SAMPLING The method of drawing representative samples of the material and criteria for conformity shall be as prescribed in Annex B.

ANNEX A ( Foreword )
NOTES FOR GUIDANCE OF USERS/DESIGNERS A-1.1.3 Protection Against Moisture A-1 GENERAL A-1.1 IS 7240 : 1981 and IS 7413 : 1981 give gui- There is a need for the application of a moisture dance on the design of thermal insulation systems. barrier to the outer surfaces of the foam when opeHowever, certain points that have special relevance rating below ambient temperature. to cellular condensation polymers and which would A-1.1.4 Adequate precautions should be taken to equally apply to rigid phenolic foams are given prevent moisture being interposed between metal below. and foam surfaces, in order to reduce possibility of corrosion. A-1.1.1 Density A-1.1.5 For normal use, rigid polyurethane foam Materials of apparent density 30 kg/m3 to 50 materials are suitable for the temperature range 3 kg/m are normally found suitable for most -- 180°C to + 130°C. thermal insulation purposes within the scope of this standard. A-1.1.5.1 Use at lower temperature A-1.1.2 Thermal Conductivity It has been established that a negligible increase in thermal conductivity occurs within the density range 30 kg/m8 to 50 kg/m3. However, the value may increase with time depending on environmental conditions ( temperature and humidity cycling, etc ). Hence, in designing insulation systems with phenolic foams care should be taken to prevent ingress of water. A-1.1.2.1 Thermal conductivity values have been reported at 53°C mean temperature to enable tests to be carried out in Indian laboratories where presently facilities for conducting tests at 10°C mean temperature by the method prescribed in IS 3346 : 1980 do not exist The lower temperature limit is selected to indicate the unsuitability of these materials for insulation of liquid oxygen plant. These materials can, however, be used at temperatures somewhat lower than --180°C provided precautions are taken to prevent condensation of atmospheric oxygen in or on the insulation. A-1.1.6 Protection Against Fire As in the case of all foam plastic insulating materials, attention of the user is drawn to the necessity of providing protection capable of withstanding possible external fires. Further, in many instances, the contribution of other system elements such as adhesives, sealants or vapour barrier mastics towards fire behaviour of the overall system could be considerable.

3

IS 13204 : 1991

ANNEX B ( Clause 7 )
SAMPLING OF RIGID PHENOLIC FOAM FOR THERMAL INSULATION B-1 SCALE OF SAMPLING B-1.1 Lot In a singal consignment all the items of the same type, shape and dimensions belong to the same batch of manufacture shall be grouped together to constitute a lot. B-1.2 For the purpose of judging conformity to the requirements of this specification each lot shall be considered separately. The number of sample items for this purpose shall depend on the size of the lot and shall be in accordance with col 1 and 2 of Table 4. B-1.3 The sample items shall be taken at random from the lot. In order to ensure randomness of selection, random number tables shall be used. In case random number tables are not available, the following procedure may be adopted: Starting from any item count all the items in the lot as 1, 2, 3,................up to r and so on in one order. Every rth item thus counted shall be withdrawn as sample item, r being the integral part of N/n where N is the number of items in the lot and n is the number of sample items to be selected. B 2 NUMBER OF TEST AND CRITERIA FOR CONFORMITY B-2.1 All the sample items selected from the lot in accordance with B-1.2 and B-1.3 shall be tested for all the requirements of this specification. Any item failing in one or more of the requirements shall be regarded as defective. B-2.2 The lot shall be declared as conforming to the requirements of this specification if the number of defective sample items does not exceed the corresponding permissible number 'a' given in col 3 of Table 4. Table 4 Scale of Sampling ( Clause B-1.2 )
Number of Items in the Lot N (1) Up to 25 26 to 100 101 to 300 301 to 1 000 1 001 to 3 000 3 001 and above Number of Sample Items n (2) 3 3 8 13 20 32 Permissible Order of Defective Sample Items a (3) 0 0 0 0 1 2

4

Standard Mark The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well defined system of inspection, testing and quality control which is devised and supervised by BIS and operated by the producer. Standard marked products are also continuously checked by BIS for conformity to that standard as a further safeguard. Details of conditions under which a licence for the use of the Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards.

Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director ( Publications ), BIS. Revision of Indian Standards Indian Standards are reviewed periodically and revised, when necessary and amendments, if any, are issued from time to time. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition. Comments on this Indian Standard may be sent to BIS giving the following reference: Doc : No. CHD 27 ( 8997 )

Amendments Issued Since Publication Amend No. Date of Issue Text Affected

BUREAU OF INDIAN STANDARDS Headquarters : Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002 Telephones : 331 01 31, 331 13 75 Regional Offices : Central: Manak Bhavan, 9 Bahadur Shah Zafar Marg NEW DELHI 110002 Eastern : 1/14 C. I. T. Scheme VII M, V. I. P. Road, Maniktola CALCUTTA 700054 Northern : SCO 445-446, Sector 35-C, CHANDIGARH 160036 Southern : C. I. T. Campus, IV Cross Road, MADRAS 600113 Western : Manakalaya, E9 MIDC, Marol, Andheri ( East ) BOMBAY 400093

Telegrams : Manaksanstha ( Common to all Offices ) Telephone 311 01 31 331 13 75 37 86 62 53 38 43 235 02 16 6 32 92 95

Branches : AHMADABAD, BANGALORE, BHOPAL, BHUBANESHWAR, COIMBATORE, FARIDABAD, GHAZIABAD, GUWAHATI, HYDERABAD, JAIPUR, KANPUR, PATNA, THIRUVANANTHAPURAM.

Printed at Printwell Printers, Aligarh, India